Sensor return container and methods for forming the same

ABSTRACT

A return container for a sensor device and methods of forming a sensor device return container are disclosed. The return container may include a container sheet, which has a plurality of panels configured to be folded around the sensor device. The panels, as folded, define at least a first region for maintaining the sensor device, and a separate second region for maintaining an accessory associated with the sensor device. At least one of the panels has a re-sealable closing system that permits repeated access to the sensor device and accessory maintained within the return container. And one of more of the panels defines at least one interface opening that provides access to a limited portion of the sensor device as it is maintained within the first region.

FIELD OF THE DISCLOSURE

The present disclosure relates to systems, apparatus and methods in the field of containers and, more particularly, for an improved sensor return container.

BACKGROUND

Cardboard boxes (i.e., a type of container) of different sizes are commonly used to ship products. One type of container used for shipping is a corrugated fiberboard box (also referred to commonly as a “cardboard box”). Among its uses, corrugated boxes may be used by manufacturers of products to ship products to retail distributors or to end users, and used by the general public to ship materials, gifts, or other items to friends and relatives.

In some situations, what is shipped in a container may be very important to the sending entity, the intended recipient, the shipping company (or companies, when it involves intermodal shipment), or all three. As such, there is commonly a need for enhanced visibility and tracking during shipping of a package in order to have better control and awareness. More specifically, there may be a need to be in control of and be aware of the environmental conditions by parties that ship and receive packages. In addition to the current location, such environmental conditions may include an accurate temperature, any light exposure to the package, the relative humidity being exposed to the package, as well as the current barometric pressure within the container and on the package being shipped within the container. More generally, it will be appreciated that the sensor device may be placed in or on a package, a container, a pallet or skid, other other shipping device or item.

The party shipping the package may want to monitor the conditions of the package in the container in order to ensure that the package arrives in a timely and appropriate condition. Likewise, the party receiving the package may want to monitor the conditions of the package to keep aware and abreast of unintended changes in the package conditions. Packages being shipped may need to be environmentally controlled to ensure, for example, freshness of shipped food or a frozen state of the shipped package.

Known logistics solutions for tracking items include bar codes and radio frequency identification (RFID) tags associated with shipped containers. Bar codes are typically placed on the outside of the container being shipped, and associated with the package within the container. A package and/or container may have a bar code corresponding to a tracking number for that package. Each time the container and package are scanned at predetermined times or checkpoints (e.g., loading of the container onto a delivery vehicle from a warehouse or delivery of the container to the intended recipient), tracking is updated for the container and package. RFID tags improve upon simple bar codes in that they do not require manual scanning. RFID tags can communicate with an electronic reader to help track things, such as livestock, railroad cars, trucks, and airline baggage.

In addition to the tracking the location of items, it is known that sensor devices may be used to track and monitor environmental conditions of the package in the shipped container, such as with the products and services from SenseAware (powered by FedEx). Such known sensor-based logistics solutions may use a powered, active sensor device placed into a container with the package being shipped. The container, with the package and activated sensor device, is shipped while the sensor device monitors conditions, stores data, and transmits information related to the environmental conditions to tracking centers. As such, the sensor device may be used solely within a single package or associated with a group of packages or containers. Additionally, those skilled in the art will appreciate that such a sensor device may not necessarily reside within container.

Once the container is received by the intended recipient, the recipient typically returns the sensor device to the shipping party. It is commonly known that shipped packages may be returned in their original container. However, shipping a sensor device back in the original container housing the package and the sensor device can be problematic. For example, the sensor device may be very small compared with the larger sized package and, thus, the original container may undesirably allow the sensor device an unrestricted freedom to move about unprotected within the original container. This may undesirably cause damage to the sensor device as the original container is moved.

Known return containers specific for sensor devices help provide a more restricted range of movement for the sensor device once placed within the return container. Typically, such known return containers are folded around the sensor device to provide a level of protection for the sensor device while still exposing parts of the sensor device outside the return container as it is shipped back to the supplier. However, there may be problematic issues with existing return containers when the sensor is used with separate accessories. Additionally, existing return containers are known to be one-time use containers and provide limited to no access to non-exposed areas of the sensor device or require separate shipping of the related accessories. Thus, there remains a need for providing optimal protection to a sensor device and its associated accessories during return while also providing improved access and functionality features and interconnections while in the return shipping configuration.

SUMMARY

In the following description, certain aspects and embodiments will become evident. It should be understood that the aspects and embodiments, in their broadest sense, could be practiced without having one or more features of these aspects and embodiments. It should be understood that these aspects and embodiments are merely exemplary.

One aspect of the disclosure relates to a return container for a sensor device. The return container generally includes a container sheet, which has multiple panels configured to be folded around the sensor device. The folded panels define at least a first region for maintaining the sensor device and a separate second region for maintaining an accessory associated with the sensor device. At least one of the panels comprises a re-sealable closing system that permits repeated access to the sensor device and accessory maintained within the return container. And one or more of the panels defines at least one interface opening that provides access to a limited portion of the sensor device as it is maintained within the first region.

In another aspect of the disclosure, another return container for a sensor device is disclosed. The return container generally includes a container sheet of protective material, such as cardboard, capable of being formed into a multi-sided holder of the sensor device that protects an exterior of the sensor device. The container sheet generally comprises a central panel and a plurality of side panels. Each of the side panels are connected to the central panel. One of the side panels has a flap with multiple fold lines, and another of the side panels has a re-sealable closing system that permits repeated access to the sensor device and accessory maintained within the improved return container. Each of the side panels is connected to the central panel along a respective edge of the central panel. When the flap is folded along the multiple fold lines, the surfaces of the folded flap along with a portion of the central panel define an accessory storage region for maintaining an accessory associated with the sensor device. The remaining side panels are configured to be folded about the central panel and, when folded with the central panel and a portion of the flap, to define a sensor device region for maintaining the sensor device.

In yet another aspect of the disclosure, a method is described for forming a sensor device return container. The return container has a central panel, two opposing panels, an end flap, and a closing flap having a re-sealable closing system. The end flap is proximate the central panel and has a plurality of fold lines and an attachment portion on an end opposite the central panel. The method begins by folding the end flap relative to the central panel along the plurality of fold lines to form an accessory region within the return container for maintaining at least one accessory associated with the sensor device. The method continues by fixing the attachment portion at end of the end flap to an interior location on the central panel. At least one accessory is placed within the accessory region of the return container.

The method continues by placing the sensor device proximate to the central panel and proximate a portion of the folded end flap located next to the attachment portion. The sensor device is desirably aligned with at least one interface opening in at least one of the central panel, the two opposing panels, and the closing flap. The interface opening is at least one from a group comprising a display opening, a control opening, and a sensor interface opening. In some situations, the sensor device may be desirably aligned with a registration element.

The method continues by folding the two opposing panels to cover at least two opposing surfaces of the sensor device, and folding the closing flap to secure the sensor device within a sensor device region defined by portions of each of the central panel, the two opposing panels, and the portion of the folded end flap located next to the attachment portion. Next, the re-sealable closing system on the closing flap is closed and a return shipping label is placed directly on the exterior of the return container without blocking or obstructing the interface opening(s) on the return container.

Additional advantages of this and other aspects of the disclosed embodiments and examples will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments according to one or more principles of the invention and together with the description, serve to explain one or more principles of the invention. In the drawings,

FIGS. 1A-1D are collectively a series of front, side, and back views of an exemplary sensor device for use with an embodiment of the invention;

FIG. 2 is an exemplary diagram of a system that monitors the exemplary sensor device of FIGS. 1A-1D in an exemplary operating environment in accordance with an embodiment of the invention;

FIGS. 3A-3D are collectively a series of diagrams illustrating different views and features of an exemplary container sheet in accordance with an embodiment of the invention;

FIGS. 4A-4E are collectively a series of perspective diagrams illustrating stages of assembling an example sensor device return container from the exemplary container sheet of FIGS. 3A-3D in accordance with an embodiment of the invention; and

FIG. 5 is a flowchart diagram illustrating exemplary steps of a method for forming a sensor device return container in accordance with an embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to exemplary embodiments. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.

In summary, the following describes various embodiments of a return container for a sensor device and a method of forming a sensor device return container as set forth herein. FIGS. 1A-1D and FIG. 2 provide details on an exemplary operating environment, which includes an exemplary sensor device to be returned after having been shipped with a package in an original container. In context of this exemplary operating environment, FIGS. 3A-3D and FIGS. 4A-E are diagrams illustrating various views of an exemplary container sheet in an unfolded configuration and as the sheet and it's panels are folded and assembled into an exemplary return container in accordance with embodiments of the invention. And, FIG. 5 is a flowchart describing steps in an exemplary method of forming a return container for a sensor device.

Referring now to FIG. 1A, a front view of an exemplary sensor device 100 is illustrated. Generally, a sensor device monitors various conditions, such as shipping conditions. In the illustrated example in FIG. 1A, sensor device 100 measures, tracks, or monitors shipping conditions relative to a package, such as environmental conditions, physical conditions, electrical conditions, and package conditions. Environmental conditions may, for example, include package or external temperature, relative ambient humidity, exposure to light (possibly indicating a damaged or otherwise compromised container or package), and barometric pressure. Physical conditions may, for example, include geographic locations (e.g., latitude/longitude coordinate tracking, altitude, status of physical orientation (e.g., upside down)) and shock impacts (possibly indicating a damaging event or abrupt force that may negatively impact the constitution or status of the container or package within the container). Electrical conditions may, for example, include on/off status (of the sensor device or package), power usage of the sensor device or the package, and battery usage. And package conditions may, for example, include other telemetry specific to parameters of the package reflecting a status of the package, such as oxygen levels in air for oxygen sensitive shipments or salinity levels in liquid for shipping salt water aquatic life.

Sensor devices, such as device 100, measure, track, and monitor the shipping conditions described above using sensors. Different types of sensor devices may rely on sensors within the sensor device itself, may rely on sensors external to the sensor device, or a combination of both. Examples of such sensors may include, but not be limited to, accelerometers, a global positioning system (GPS) receiver, current/voltage monitors, pressure sensors, light sensors, temperature sensors, chemical detectors, gas detectors, and the like.

As shown in FIG. 1A, exemplary sensor device 100 includes a display interface 105 (such as LED display), a control interface 110 (such as an on/off button), and a sensor interface 115. The display interface 105, very generally referred to as an informational status indicator, serves to provide an outward, but local indication of the sensor device's status or other information (e.g., shipping condition data related to the package). Beyond the display interface, the sensor device 100 may communicate the shipping condition data to further remote recipients via wired connections (e.g., connections 135 a, 135 b shown in FIG. 1C and described in more detail below) or wireless communication systems (e.g., a GSM cellular transceiver within the sensor device communicative within a system as illustrated in FIG. 2). One skilled in the art will appreciate that other types of informational status indicators or display interfaces may be used, such as one or more status lights (incandescent, LED, LCD), a speaker (audio status), or other types of information interfaces that may show or communicate the information, such as the status of the device or any part of the shipping condition data.

Additional examples of different control and sensor interfaces are shown in FIGS. 1B-1D. Referring now to FIG. 1B, a side view of sensor device 100 is shown that illustrates battery sensors 120 a, 120 b as another type of sensor interface. Battery sensors 120 a, 120 b allow for an interface to the onboard battery (not shown) within the sensor device 100. Additionally, those skilled in the art will appreciate that such sensors 120 a, 120 b allow for re-charging of the battery without removing the battery from the device 100.

FIG. 1C illustrates control interfaces 135 a and 135 b disposed in a view of another side of exemplary sensory device 100. In this embodiment, sensor device 100 includes a re-sealable housing 125 as part of the device 100 where a sealing cover 130 may be used to provide a level of environmental protection for the otherwise exposed control interfaces 135 a, 135 b. Examples of such control interfaces 135 a, 135 b may include wired data communication connections (e.g., micro USB ports, serial connector, parallel connectors, etc.) where a communication pathway may be connected to the interface in order to interact with onboard sensing, tracking, monitoring, and control electronics (e.g., a processor-based system with volatile and non-volatile memory, and interfaces to sensors and sensor interfaces) outside of or in addition to any wireless communication pathways to and from the sensor device 100. Alternative embodiments may include other control interfaces, such as a memory card reader (i.e., removable memory cards that may load digital information, such as programs or control data, into sensor device 100 or that may receive digital information, such as shipping condition data, from the sensor device 100) or other interfaces that provide input used to control sensor device 100 or receive output from sensor device 100.

FIG. 1D illustrates a back view of exemplary sensor device 100, and shows another sensor interface 140 that detects light. Other sensors, not shown, may be disposed at interfaces strategically in locations all around the sensor device 100. Thus, while exemplary sensor device 100 is shown with particular control, display, and sensor interfaces, those skilled in the art will realize that embodiments of the present invention can work with a variety of sensor devices that have alternative arrangements and types of control, display, and sensor interfaces.

As noted above, different types of sensor devices may rely on sensors external to the sensor device. While not shown in FIGS. 1A-1D, an embodiment of sensor device 100 may include a remote sensor interface for an external sensor (e.g., an external temperature probe). In such embodiments, the external accessory related to the sensor device 100 connects to sensor device 100 through the remote sensor interface on the device. For example, a dry ice probe sensor accessory may be used to enable near real-time monitoring of dry ice shipments within the original shipping container that need to be kept within a very specific temperature range.

While a probe or other external sensor is more generally considered a type of accessory for the sensor device 100, those skilled in the art will appreciate that the term “accessory” is used broadly and may, at least, include any external items that may be useful in the operation of the sensor device 100. For example, other examples of an accessory may be a communication cable that may fit into control interfaces 135 a or 135 b, a charging device or cabling that facilitates charging of the sensor device 100, and other external sensors, probes, gauges, or other data acquisition related devices, equipment or cabling that are associated with operations of the sensor device 100.

Exemplary sensor device 100, when in operation, may interact with external devices to communicate the shipping condition data being monitored. FIG. 2 is an exemplary diagram of a system that monitors the exemplary sensor device of FIGS. 1A-1D in accordance with an embodiment of the invention. Referring now to FIG. 2, sensor device 100 communicates with an exemplary client 205 and an exemplary tracking center 210 via a network 200. In general, network 200 provides the communication pathways (e.g., hardwired, optical, wireless, satellite, cellular, shared, public, private, etc.) that enables such communication between the sensor device 100 and exemplary external monitoring entities as client 205 (such as the shipping entity or intended recipient) and the tracking center 210. Tracking center 210 may receive and send instructions to and from the sensing device 100, as well as manage requests from the client 205 for updates or status of shipping conditions related to sensor device 100. More details regarding an exemplary sensor device, and a system and method of monitoring such a sensor device is further disclosed in U.S. Pat. No. 8,239,169, which is hereby incorporated by reference.

During shipment to the intended recipient, the sensor device 100 may be attached to or included with the package within the original shipping container. But once the sensor device 100 and its associated accessory (or accessories) has arrived at the intended destination, the need for a return container arises. As discussed above, using the original shipping container as a return container for the sensor device 100 often has undesirable effects on the safe and efficient return of the sensor device 100. FIGS. 3A-3D are collectively a series of diagrams illustrating different views of an exemplary container sheet that may be configured as an exemplary return container for a sensor device in accordance with an embodiment of the invention.

Referring now to FIG. 3A, exemplary container sheet 300 has a central panel 310 and multiple side panels attached to respective edges of central panel 310. Container sheet 300 may be implemented with a variety of materials that may be formed to provide a protective return container in accordance with principles of the present invention. In one embodiment, container sheet 300 is made from corrugated fiberboard material commonly referred to as cardboard. However, other embodiments may use a different protective material for container sheet 300, or a combination of materials. For example, the material for container sheet may include an inner material that is more fitted to the exterior of the sensor device 100 while an outer material may be used that is stiffer in comparison and better at protecting sensor device 100 from damage due to shocks and other physical forces on the return container.

In one embodiment, the side panels include flap 305, opposing side panels 315, 320, and closing flap 325. Such side panels are shown attached to edges of central panel 310 with a demarcation between each respective side panel and the central panel 310. In one embodiment, the demarcation represents a fold line that facilitates and eases folding of the side panel relative to the central panel 310. In some embodiments, one or more of the side panels may include multiple fold lines so that the side panel may be divided or folded into different subpanel. In yet other embodiments, the demarcation may be supported with tape that helps maintain a strong joint between the central panel 310 and the respective side panel.

In one embodiment, flap 305 includes three vertically-oriented fold lines as shown in FIG. 3A, which separates flap 3 into distinctly separate (yet still attached) subpanels (i.e., attachment portion 330 and remaining subpanels 345 a, 345 b, and 345 c that make up flap 305). In one embodiment, the end subpanel of flap 305 is deemed the attachment portion 330 because it is the part of flap 305 that is folded over and attached to a location on central panel 310. More specifically, exemplary flap 305 is configured to be folded along the multiple fold lines 3430 such that the surfaces of subpanels 345 a, 345 b, and 346 c along with a portion of central panel 310 form or otherwise define a space or region within the return container to maintain one or more accessories associated with sensor device 100.

This accessory storage region provides a separate storage area for such accessories within the return container for the sensor device 100. As will be explained in more detail below with respect to FIG. 4B, accessories may be stored within this region on one side of subpanel 345 c while the sensor device 100 may be placed proximate the other side of subpanel 345 c. In one embodiment, subpanel 345 c is thus a type of separator. In another embodiment, subpanel 345 c may include one or more openings (not shown) that provide direct access between the respective regions holding the accessory and the sensor device 100. This may be advantageous for situations when it is desired to connect one or more accessories to the sensor device 100 during return shipment.

In another embodiment, another separator may be used to compartmentalize different accessories within the accessory storage region. For example, subpanels 345 b or 345 c may include a “U” shaped perforation (not shown) that helps form a separator when the material within the “U” shaped perforation is extended perpendicular to the plane of its respective subpanel. As such, this separator portion of subpanels 345 b or 345 c may extend within the accessory storage region and act as an additional separator used to segregate and maintain different accessories within different subregions or areas within the accessory storage region. Depending upon the type of sensor device and the accessories to be shipped back in the return shipment, an embodiment may include openings in each of the subregions to the sensor device so that different sensors in different subregions of the storage region may still have respective direct access to the sensor device while remaining within the return container. Those skilled in the art will appreciate that such a configuration provides for an advantageously compact and multi-functional return container that can accommodate different sized accessories and different operations of the sensor device 100 during its return shipment.

In another embodiment, attachment portion 330 may include an additional registration feature that may be folded and configured into a registration element (not shown) with respect to the sensor device 100. For example, a part of attachment portion 330 may be cut and folded so as to extend up from being coplanar with central panel 310. By at least extending up and otherwise extending into and obstructing a portion of the available region for maintaining the sensor device when encapsulated within the return container, the extending or obstructing structure defined by the part of the attachment portion 330 (or parts of attachment portion 330 and subpanel 345 a) operates as a registration element to assure proper aligned insertion or placement of the sensor device 100 in the return container. As such, sensor device 100 may only fit within the return container is a desired orientation, which physically provides an alignment of interfaces with interface openings in the return container. While visual alignment of the sensor device within the return container relative to the interface openings is possible, use of a registration element particular to the specific intended sensor device for the return container may be further advantageous at avoiding unintended misalignment when assembling the return container requiring. Additionally, such a registration element may proactively help avoid performance issues during return shipment of the sensor device within the return container (e.g., blocking of sensors).

In the embodiment illustrated in FIG. 3A, closing flap 325 extends opposite from flap 305 and is connected or otherwise disposed along an edge proximate to the central panel 310 of container sheet 300. Closing flap 325 also includes several fold lines that facilitate folding of flap 325 into subpanels and a tab 335, which is part of an exemplary re-sealable closing system. In conjunction with tab slit 350 disposed between central panel 310 and flap 305, the exemplary re-sealable closing system is implemented by inserting tab 335 into slit 350 once the flap 325 is folded and configured to overlap on top of central panel 310. In one embodiment, slit 350 is a locking tab slit that provide a desired level of frictional forces to retain the tab within the slit. Other embodiments may implement the re-sealable closing system with multiple tab/slit combinations, use sealing tape that may be removed without damaging the return container, or other known mechanisms to close flap 325 relative to the space defined within (i.e., the region for the sensor device 100 and the accessory storage region) and maintain flap 325 relative to at least subpanel 345 b, but allow later access to the return container's interior regions without destructive action on the return container.

In an alternative embodiment, flap 325 does not extend over subpanel 345 c, and instead, allows for a second but separate re-sealable closing system on flap 305 to provide separate access to the distinct accessory storage region without providing direct access to where the sensor device 100 is placed and covered by closing flap 325. For example, a slit (not shown) may be included between subpanels 345 a and 345 b to provide a receptacle for the closing tab 335 on shortened closing flap 325. In that example, a second access may be provided on subpanel 345 c by a portion of that subpanel being free to extend outward and external from the accessory storage region via cuts in the subpanel and fold lines facilitating the extension of that portion of the subpanel.

In addition to the re-sealable closing system, closing flap 325 also includes multiple interface openings that each provides access to a limited portion of the sensor device as it is maintained within the return container. The interface openings specifically are positioned to align with interfaces (e.g., controls, displays, sensors, remote sensor interfaces, or other connections) on a sensor device when the device is placed within the return container configured from sheet 300. For example, closing flap 325 includes interface opening 360 a as a display opening that aligns with display interface 105, interface opening 375 that aligns with control interface 110, and interface opening 365 a that aligns with sensor interface 115. Likewise, interface openings 360 b, 365 b, 370 and 380 on the center panel 310 and opposing side panels 315, 320 align with other interfaces on sensor device 100.

While FIG. 3A shows exemplary dimensions for features of exemplary container sheet 300, FIG. 3B illustrates the same inside surface of exemplary container sheet 300 without the dimensions but in an embodiment showing sample text that may be affixed to the inside surface of container sheet 300. Referring now to FIG. 3B, exemplary container sheet 300 includes sample text that may identify a supplier of the sensor device and/or the return container, assign basic labels to different parts of the container 300 (e.g., specific tabs or flaps), set forth user instructions for assembling the return container, and relevant contact information. The sample text may also provide instructions with respect to placement and alignment of the sensor device 100 with respect to the container sheet and its interface openings.

FIG. 3C is yet another view of exemplary container sheet 300 in an embodiment, but illustrates an exterior surface. In other words, FIG. 3C illustrates exemplary container sheet 300 and its features (e.g., fold lines presented in dashed lines, cut lines presented in solid lines, and various interface openings) in an embodiment with no shading or return label area appearing on the exterior surface of the sheet 300. However, FIG. 3D illustrates another embodiment of sheet 300 showing an exterior surface where desired shading may be placed on various surfaces of the side panels and a return label area 385 is identified. The text appearing in the return label area 385 may help assist the recipient of sensor device 100 in placement of the return label while avoiding any overlap of an interface opening in the assembled return container.

FIGS. 4A-4E are collectively a series of perspective diagrams illustrating stages of assembling an example sensor device return container from the exemplary container sheet 300 of FIGS. 3A-3D in accordance with an embodiment of the invention. Referring now to FIG. 4A, exemplary container sheet 300 is illustrated with central panel 310 remaining flat as side panels 305, 315, 320, and 325 are folded up along score or fold lines along the respective intersections of the side panels and the central panel 310. In FIG. 4B, an end flap side panel 305 is folded relative to the central panel 310 along a plurality of fold lines on flap 305. This places subpanels 345 a, 345 b, and 345 c at substantially right angles between proximate subpanels, and has the attachment portion 330 in planar proximity to central panel 310. As such, subpanels 345 a, 345 b, and 345 c along with a portion of central panel 310 substantially form or otherwise define an accessory region 405 within the return container being assembled from container sheet 300.

The accessory region (also referred to as an accessory storage region) maintains at least one accessory associated with the sensor device. One or more accessories may be placed within region 405 for safe return with the sensor device 100. Additionally, as previously mentioned, another embodiment may include a separator that extends from one of the subpanels to divide the accessory region 405 into distinct subregions, so as to accommodate and individually protect multiple accessories. Further still, yet another embodiment may provide an opening or other selective access (e.g., via perforations or selective knockout regions) through subpanel 345 a in order to facilitate connection of at least one stored accessory to sensor device 100 while the sensor device 100 is maintained within the return container formed from sheet 300.

In the configuration shown in FIG. 4B, attachment portion 330 may be fixed to an interior location on the central panel 310. In one embodiment, a suitable adhesive, such as a hot melt glue, or other known means for fixing two cardboard surfaces to each other, is applied to attachment portion 330 or the interior location on the central panel 310 before the central panel 310 and attachment portion 330 are fixed relative to each other. Alternative embodiments may fix the central panel 310 and attachment portion 330 relative to each other in a non-permanent manner, such as with one or two-sided tape or gripping surfaces (such as hook and loop fasteners).

FIG. 4C illustrates a perspective view of another stage of assembling the exemplary return container from exemplary container sheet 300. Referring now to FIG. 4C, sensor device 100 may be placed in a region 410 proximate to the interior surface of central panel 310 and proximate to a portion of the folded end flap (e.g., subpanel 345 a) located next to the attachment portion 330. When placing the sensor device 100 within region 410, it is advantageous to visually align features of the sensor device 100 with one or more corresponding openings (e.g., interface openings) on the sheet 300. In one embodiment, such openings may include a display opening, a control opening, and a sensor interface opening. In another embodiment, a portion of flap 305 may extend into region 410 in a manner to complement the exterior configuration of sensor device 100 as it fits within region 410 and function as a registration structure to help physically align and ensure advantageous orientation of sensor device 100 as it is placed within region 410.

Once sensor device 100 is placed within region 410 (more generally referred to as a sensor device region), opposing side panels 315 and 320 may be folded relative to each other to cover at least two opposing surfaces of the sensor device. For example, in one embodiment side panel 315 may simply have no fold lines and fold up from an original co-planar orientation with central panel 310. As such, when folded up to a substantially perpendicular orientation relative to central panel 310, side panel 315 at least covers one side exterior surface of sensor device 100 disposed within region 410 and side panel 320 does likewise. In another example, such as that shown in FIG. 4C, exemplary side panels 315, 320 include various fold lines such that when folded, allows the respective opposing side panels to cover more than one exterior surface of sensor device 100 and, as a result, provide additional stability and cushioning for the assembled return container.

FIG. 4D illustrates a perspective view of a stage of assembling the exemplary return container from sheet 300 where the closing flap (more generally referred to as panel 325) is folded to secure the sensor device 100 within region 410 defined by portions of each of the central panel 310, the two opposing panels 315, 320, and the portion of the folded end flap (i.e., subpanel 345 a) located next to the attachment portion 330 of flap 305. As shown, different related interface openings from different panels of sheet 300 align to provide advantageous but limited access to sensor device 100 while in the assembled return container.

As shown in FIG. 4E, the re-sealable closing system on closing flap 325 and flap 305 has been closed. In the illustrated embodiment, tab 335 is inserted within slot 250 as part of this exemplary closing system. Those skilled in the art will appreciate other tab/slot configurations or other known manners of closing a container in a re-sealable manner that will be equally applicable and in accordance with other embodiments. Those skilled in the art will also appreciate that a re-sealable closing system allows repeated access to the interior of the return container without requiring a destructive action to be taken on a portion of the container. For example, while providing a rip or tear mechanism on an exterior surface of the return container to close the container is possible and may prevent repeated access to within the return container (e.g., for potential enhanced security purposes), doing so means the return container is a one-time sealed entity. As such, it cannot be re-opened to adjust alignment, insert additional accessories, or make/adjust connections between external accessories stored within region 405 and the sensor device 100.

Once the sensor device 100 and one or more accessories are respectively placed in regions 410 and 405, the exemplary return container assembled from sheet 300 may have a return shipping label placed on the exterior surface of sheet 300. In one embodiment, there are textual instructions on where to place the label such that it does not obstruct or otherwise interfere with the interface openings that expose sensor device interfaces (e.g., the on/off switch, the light sensor, external temp probe accessory connections, external antenna connections, etc.)

Further details on the assembly operation of particular embodiments are illustrated through a general flowchart of FIG. 5. In particular, FIG. 5 is a flowchart diagram illustrating exemplary steps of a method for forming a sensor device return container in accordance with an embodiment of the invention. The sensor device return container has a central panel, two opposing panels, an end flap, and a closing flap having a re-sealable closing system. The end flap is proximate the central panel and has a plurality of fold lines and an attachment portion on an end opposite the central panel. In the context of this exemplary sensor device return container, method 500 is discussed as follows.

In particular, method 500 begins at stage 505 by folding the end flap relative to the central panel along the fold lines to form an accessory region within the return container for maintaining at least one accessory associated with the sensor device. For example, as illustrated in FIG. 4B and described above, region 405 is formed by folding end flap 305 relative to central panel 310. At stage 510, the attachment portion at end of the end flap is fixed relative to an interior location on the central panel. For example, as discussed with respect to the example in FIG. 4B, fixing may be accomplished with hot glue, other adhesives, or other temporary or more permanent means (e.g., one or two sided tapes, hook & loop fastening materials like Velcro® brand products) that hold attachment portion 330 in at least a temporary fixed relationship relative to a location on central panel 310.

At stage 515, at least one accessory may be placed within the accessory region of the return container. In one embodiment, a single accessory is accommodated within the accessory region. In another embodiment, more than one accessory may be placed within the accessory region. In yet another embodiment, a separator structure may be extended or otherwise placed within the accessory region to separate the region into distinct subregions for different accessories. In more general terms, a separator portion of the end flap may be extended within the accessory region to define a first subregion and a second subregion such that a first accessory may be placed within the first subregion of the accessory region and a second accessory may be placed within the second subregion of the accessory region.

And in yet another embodiment, a portion of the panel material forming the accessory region may include an access opening that allows an accessory placed within the accessory region to be connected to the sensor device while packaged within the return container.

At stage 520, the sensor device is placed proximate to the central panel and proximate to a portion of the folded end flap located next to the attachment portion. For example, in the illustrated embodiment of FIG. 4C, the sensor device 100 may be placed within region 410, which is proximate to the interior surface of central panel 310 and proximate to a subpanel 345 a of the folded end flap 305 located next to the attachment portion 330.

The sensor device should be aligned with at least one interface opening (e.g., a display opening, a control opening, and a sensor interface opening) in at least one of the central panel, the two opposing panels, and the closing flap. Stage 525 allows for confirming alignment of the sensor device relative to the interface openings. In one embodiment, such alignment may be visually confirmed with inspection of the sensor device's interfaces and the return container's interface openings. In another embodiment, such alignment may be facilitated through the use of portions of any of the subpanels that extend within region 410 to operate as registration elements that permit only aligned placement of sensor device 100 within region 410.

At stage 530, the two opposing panels are folded to cover at least two opposing surfaces of the sensor device. In one embodiment, such as that illustrated in FIG. 4C, opposing side panels 315 and 320 are folded to cover at least various side exterior surfaces of sensor device 100 when placed within region 410.

At stage 535, the closing flap is folded to secure the sensor device within a sensor device region defined by portions of each of the central panel, the two opposing panels, and the portion of the folded end flap located next to the attachment portion. In one embodiment, the sensor device region corresponds to region 410, which is defined when closing flap 325 is folded over sensor device 100 as the return container from sheet 300 is assembled as shown in FIGS. 4C-4D.

At stage 540, the re-sealable closing system on the closing flap is closed to complete the configuration of the container sheet into the sensor device return container. For example, as shown in FIG. 4D, tab 335 is inserted within slit 350 to close the re-sealable closing system. Finally, at stage 545, a return shipping label is placed directly on the exterior of the return container without blocking an interface opening.

It should be emphasized that the sequence of operations to assemble the exemplary return container for a sensor device described herein (such as those set forth above with respect to FIG. 5) is merely an example, and that a variety of sequences of operations to form such a return container may be followed while still being true and in accordance with the principles of the present invention. For example, in general, the sequence of operations may depend upon the size and shape of the sensor device, and the size, shape, and material of the return container. Different sized and shaped sensor devices may permit more elaborate folds, perforations, cuts, openings, and/or opening & closing systems while still being embodiments of the present invention.

At least some portions of exemplary embodiments outlined above may be used in association with portions of other exemplary embodiments. Moreover, at least some of the exemplary embodiments disclosed herein may be used independently from one another and/or in combination with one another and may have applications to devices and methods not disclosed herein.

Those skilled in the art will appreciate that embodiments may provide one or more advantages, such as an advantageously compact and multi-functional return container that may, depending upon the particular embodiment, accommodate different sized accessories, different operations of the sensor device during return shipment, may help avoid the need for wasted return containers, may be re-opened to adjust alignment, insert additional accessories, or make/adjust connections between external accessories stored within an internal accessory region and the packaged sensor device. Additionally, while the above described embodiments explain the principles of the present invention in terms of a flexible cardboard return container, embodiments of the invention may also be applied to other materials for the container sheet.

It will be apparent to those skilled in the art that various modifications and variations can be made to the structures and methodologies described herein. Thus, it should be understood that the invention is not limited to the subject matter discussed in the description. Rather, the present invention is intended to cover modifications and variations. 

What is claimed is:
 1. A return container for a sensor device, comprising: a container sheet of protective material capable of being formed into a multi-sided holder of the sensor device that covers and protects a majority of the exterior surface of the sensor device, the container sheet comprising a central panel and a plurality of side panels each of which are connected to the central panel, one of the side panels comprising a flap with multiple fold lines, and another of the side panels comprising a re-sealable closing system that permits repeated access to the sensor device and accessory maintained within the return container; wherein each of the side panels being connected to the central panel, the side panels being respectively disposed along different edges of the central panel; wherein when the flap is folded along the multiple fold lines, the surfaces of the folded flap and a portion of the central panel define an accessory storage region for maintaining an accessory associated with the sensor device; and wherein the remaining side panels are configured to be folded about the central panel to define, with the central panel and a portion of the flap, a sensor device region for maintaining the sensor device.
 2. The return container of claim 1, wherein one or more of the central panel and side panels having at least one interface opening that provides access to a limited portion of the sensor device.
 3. The return container of claim 1, wherein the portion of the flap includes at least one opening to provide access between the accessory storage region and the sensor device region.
 4. The return container of claim 1, wherein flap includes an access system exposed to the exterior of the return container that provides access to the accessory storage region without providing direct access to the sensor device region.
 5. The return container of claim 1, wherein the flap further comprises a plurality of perforations and additional fold lines that define a separator extending into the accessory storage region when folded relative to the remainder of the flap, the separator dividing the accessory storage region into a plurality of subregions within the accessory storage region, each of the subregions for maintaining different sensor accessories associated with the sensor device.
 6. The return container of claim 1, wherein the re-sealable closing system comprises a closing flap and at least one subpanel proximate the central panel, the closing flap having at least one tab that engages another of the side panels when the panels are folded around the sensor device to form the sensor device region.
 7. A method of forming a sensor device return container having a central panel, two opposing panels, an end flap, and a closing flap having a re-sealable closing system, the end flap being proximate the central panel and having a plurality of fold lines and an attachment portion on an end opposite the central panel, the method comprising: folding the end flap relative to the central panel along the plurality of fold lines to form an accessory region within the return container for maintaining at least one accessory associated with the sensor device; fixing the attachment portion at end of the end flap to an interior location on the central panel; placing the at least one accessory within the accessory region of the return container; placing the sensor device proximate to the central panel and proximate to a portion of the folded end flap located next to the attachment portion, the sensor device being aligned with at least one interface opening in at least one of the central panel, the two opposing panels, and the closing flap, the interface opening being at least one from a group comprising a display opening, a control opening, and a sensor interface opening; folding the two opposing panels to cover at least two opposing surfaces of the sensor device; folding the closing flap to secure the sensor device within a sensor device region defined by portions of each of the central panel, the two opposing panels, and the portion of the folded end flap located next to the attachment portion; closing the re-sealable closing system on the closing flap; and placing a return shipping label directly on the exterior of the return container without blocking the at least one interface opening.
 8. The method of claim 7 further comprising: extending a separator portion of the end flap within the accessory region to define a first subregion and a second subregion; and wherein the placing step comprises placing a first accessory within the first subregion of the accessory region and placing a second accessory within the second subregion of the accessory region.
 9. A return container for a sensor device, comprising: a container sheet comprising, a plurality of panels configured to be folded around the sensor device, the panels as folded defining at least a first region for maintaining the sensor device and a separate second region for maintaining an accessory associated with the sensor device, wherein at least one of the panels comprises a re-sealable closing system that permits repeated access to the sensor device and accessory maintained within the return container; and wherein one or more of the panels defining at least one interface opening that provides access to a limited portion of the sensor device as it is maintained within the first region.
 10. The return container of claim 9, wherein the plurality of panels comprises a central panel and at least one of the remaining panels proximate the central panel comprises a flap having at least two fold lines that separate the flap into at least three subpanels, wherein the three subpanels and at least a portion of the central panel define the separate second region for maintaining the accessory.
 11. The return container of claim 10 wherein the flap has three fold lines that separate the flap into at least the three subpanels and an attachment portion of the flap, the attachment portion being attached to a location on the central panel.
 12. The return container of claim 10, wherein the one of the three subpanels disposed between the first region and the second region includes at least one opening to provide access between the first region and the second separate region.
 13. The return container of claim 10, wherein at least one of the three subpanels includes an opening system exposed to the exterior of the return container that provides access to the separate second region without providing direct access to the first region.
 14. The return container of claim 9, wherein the folded panels further define a plurality of subregions within the separate second region, each of the subregions for maintaining one of a plurality of accessories associated with the sensor device.
 15. The return container of claim 9, wherein the interface opening comprises at least one from the group comprising a display opening, a control opening, and a sensor interface opening.
 16. The return container of claim 15, wherein the display opening further comprises an opening aligned with an informational status indicator on the sensor device that displays status information associated with the sensor device.
 17. The return container of claim 15, wherein the control opening further comprises an opening aligned with at least one control interface on the sensor device.
 18. The return container of claim 15, wherein the sensor interface opening further comprises an opening aligned with at least one sensor on the sensor device to expose the at least one sensor to the exterior of the return container.
 19. The return container of claim 15, wherein the sensor interface opening further comprises an opening aligned with a remote sensor interface on the sensor device.
 20. The return container of claim 17, wherein the re-sealable closing system is proximate a central one of the plurality of panels, the re-sealable closing system further comprising a closing flap and at least one subpanel proximate the central one of the panels, the closing flap having at least one tab that engages another of the panels when the panels are folded around the sensor device. 